Vauxhall Workshop Service and Repair Manuals

Transmission Housing, Replace  

Remove transmission - refer work instruction "Removal and re-mounting of transmission". KM-444-B (65 Nm) and KM-489 to transmission; Transmission to transmission support.  

  Disassemble   

Remove plug (arrow), insert KM-527 or KM-527-A into adjuster bore and engage by turning shift rod towards 3rd gear. Shift cover from transmission (4 bolts).

Only with F 18/F 18+ transmissions:  

  Remove, Disconnect   

Rocker arm for gear set brake - release retaining pin using small screwdriver and remove in direction of arrow.   Remove rocker arm for gear set brake.

All transmissions:  

  Remove, Disconnect   

Remove end shield cover from end shield.  

F 15 only: Note fit bolts in end shield cover.  

All transmissions: Remove end shield with main and drive shaft from transmission housing.     Disassemble    Differential from transmission. Clutch thrust bearing, clutch fork, clutch release lever and clutch thrust bearing guide.   F 10/F 13/F 16/F 20 only: Cover for clutch from transmission. Both bearing bushings for clutch release lever, KM-304.   F 15/F 18/F 18+ only: Remove bearing bushings using pliers.   Speedometer helical gear (driven) - refer work instruction "O-Ring for Speedometer Helical Gear (Driven) Replacement".

F 10/F 13/F 15 manual transmission:  

  Remove, Disconnect   

Drive needle bearing for mount of drive shaft with KM-454-1 and KM-454-4 out of transmission housing.

  Install, Connect   

Drive in needle bearing for mount of drive shaft with the printed side towards transmission with KM-454-2 and KM-454-4 flush.

  Remove, Disconnect   

Needle roller bearing for main shaft, KM-556-A or Kukko Remover 21/4 with counter support 22-1.

  Install, Connect   

Drive in needle bearing for mount of main shaft flush with KM-454-3 and KM-454-4.

With F 16/F 18/F 18+/F 20 manual transmission:  

  Remove, Disconnect   

Needle roller bearing for drive shaft from transmission housing, KM-523-1 and KM-523-3.   Outer roller bearing ring for main shaft, KM-J-26941 (1), KM-483 (2) and KM-313 (3).     Important!    If stiff, heat transmission housing with hot air blower. If bearings are damaged on removal, replace with new ones.     Install, Connect

Drive in needle roller bearing for drive shaft with lettered side towards transmission flush, KM-523-1 and KM-523-2.   Press (not drive) in outer roller bearing ring for main shaft up to stop, KM-523-1 and KM-523-4.   F 16 using KM-523-1 and KM 523-4. F 18/F 18+/F 20 using KM-J-8092 and KM-743.

  Install, Connect   

F 10/F 13/F 16/F 20 only: Drive in both bearing bushings for clutch release lever, KM-304.   F 15/ F 18/F 18+ only: Push in both bearing bushings for clutch release lever using screwdriver.   With all transmissions: The cams of the bushings must sit in the transmission recesses. Lubricate bushings inside, molybdenum sulphide paste.   Install differential - see operation "Differential, Remove and Install".   Insert end shield with main and drive shaft into transmission.     Tighten (Torque)    BILD_TEXT_START ILLUS_START ILLUS HEIGHT="85" FRAME="85X100" DTH="100" ILLUSID="E6067" TYPE="TIFF" ROTATION="0" ILLUS_END   End shield and end shield cover to transmission   All gear-boxes excluding F 18 - tightening torque   M7 x 1.0   15 Nm/11 lbf. ft.     M8 x 1.25   20 Nm/15 lbf. ft.   Gear-box F 18 - tightening torque   M7 x 1.0   15 Nm/11 lbf. ft.     M8 x 1.25   20 Nm/15 + 40 ° 1)      1)  New attaching bolts

BILD_TEXT_END 

  Important!   

F 15 transmission: Note fit bolts (arrows).     Install, Connect    With all transmissions: clutch thrust bearing guide, 5 Nm/4 lbf. ft., clutch release lever to transmission, clutch fork to clutch release lever - tightening torque 35 Nm/26 lbf. ft., clutch thrust bearing to clutch fork.   For F 10-, F 13-, F 16-, F 20-manual transmission:   Closing cover for clutch to transmission   Sheet metal version, 12 Nm/9 lbf. ft.     Light alloy version, 6 Nm/4 lbf. ft.

Only with F 18/F 18+ transmissions:  

  Install, Connect   

Insert rocker arm (1) and secure with retaining pin in direction of arrow.

All transmissions except F 18. Shift cover to transmission (measurement necessary) - see "Shift Cover, Assemble and Install". Remove KM-527 temporarily from adjusting bore and insert plug (arrow).   All transmissions: Remove transmission from KM-444-B and KM-489.   Installing transmission - see operation "Transmission, Remove and Install".